the biofit project retrofitting of the bioethanol industry

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 817999.

The BIOFIT Project –Retrofitting of the

bioethanol industryVIRTUAL SEMINAR ON LIGNOCELLULOSIC ETHANOL RETROFITS

25th November 2020

Ana Susmozas, CIEMAT

www.biofit-h2020.eu 2

CIEMAT

• Public Research Body under the Ministry of Science and Innovation

• RD&I in the fields of Energy, Environment and Technology, including

sociotechnical aspects, and in specific areas of Basic Research

Human resources ≈ 1250 people

Budget ≈ 88 M€

Income generated by R&D activities (2019) ≈ 29 M€


CIEMAT SITESCIEMAT SITES

CIEMAT-Soria

CIEMAT- Extremadura

CIEMAT - Barcelona

CIEMAT-Almería

Centro de Desarrollo de Energías Renovables -CEDER

Centro Extremeño de Tecnologías Avanzadas (CETA)

CIEMAT-Madrid

Ciemat-Moncloa Headquarters

Centro de

Investigación

Socio-Técnica

(CISOT)

Plataforma Solar de Almería (PSA)

http://www.zonu.com/fullsize/2009-12-02-11288/Mapa-fisico-de-Espana.html

ADVANCED BIOFUELS AND BIOPRODUTS UNIT

Research Lines• Development of different biological processes for the conversion of lignocellulosic biomass into liquid biofuels and

bioproducts.

• Hydrothermal and thermomechanical technologies for biomass pretreatment

• Hydrolysis of carbohydrates by biological catalysts

• Fermentation of resulting sugars by microorganisms

• Techno-economic analysis of energy systems based on lignocellulosic biomass, especially those focused on obtaining

biofuels and bioproducts

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THE BIOFIT PROJECT Bioenergy Retrofits for Europe‘s Industry BioenergyRetrofits for Europe‘s Industry


• Retrofitting – which means replacing a part of a factory or installation with state-of-the-art equipment – is a good alternative to new plants for replacing fossil fuels, upgrade outdated technology, or producing additional output from biomass.

• Bioenergy retrofitting could provide significant benefits compared to building new plants, notably lower capital expenditure, shorter lead times, faster implementation, and less production time loss.

What is RETROFITTING?

THE BIOFIT PROJECTBIOENERGY RETROFITTING IN EUROPE’S INDUSTRY


The BIOFIT project aims to facilitate the market uptake of bioenergy retrofitting

concepts in several specific industrial sectors in Europe:

First generation biofuels

Pulp and paper

Fossil refienries

Fossil firing power plant

Combined Heat and Power plants

A core activity of BIOFIT is to develop 10 concrete case studies together with industrial partners.

1G Bioethanol industry

THE BIOFIT PROJECT- BIOETHANOL INDUSTRYBIOETHANOL MARKET OVERVIEW IN EU


During the last years:

Share of bioethanol in petrol≃ 5%

Bioethanol production and consumption

increase slightly.

Between 2018 and 2019, bioethanol

consumption dedicated to transport

increased by 6.4%.

THE BIOFIT PROJECT- BIOETHANOL INDUSTRYBIOETHANOL MARKET OVERVIEW


• In 2019, 48.6 % of bioethanol was produced from corn, followed by wheat and sugar -->1G BIOETHANOL

• Concerns over the long-term sustainability of 1G bioethanol: Competition for food and feed

production Impacts on land use Water resource

THE BIOFIT PROJECT- BIOETHANOL INDUSTRYADVANCED BIOETHANOL


• Lignocellulosic biomass is one of the mostabundant renewable sources

• Feedstocks not linked to the food market, many of them residues (agricultural and forest residues, residues from agroindustries(pulp and paper, food…), organic fraction of municipal solid wastes (MSW), or energy crops

• Lower lifecycle CO2 emissionssustainabilitycriteria

• Possibility to obtain high-added value products

WHY BIOETHANOL FROM LIGNOCELLULOSIC BIOMASS?

High added valueproducts

Process energy SugarsCellulose(glucose)

Lignin

Others (ash, extractives,..)

Hemicellulose(C5 & C6 sugars)

Raw material

30-45%

20-30%

15-25%

RENEWABLE ENERGY DIRECTIVE II

(RED II)

• Promote the transition from crop/food-based biofuels to biofuels from non-food feedstock:

• Within 14% renewable energy target in transport sector, minimum shares for advanced biofuels has been stablished: 0.2% (2022), 1% (2025) and 3.5% (2030).

• Limitation for food-based biofuel up to a maximum of 7%.

THE BIOFIT PROJECT- BIOETHANOL INDUSTRY

THE BIOFIT PROJECT- BIOETHANOL INDUSTRYOPPORTUNITIES FOR RETROFITTING


Policies are the main driver to promote the transition from 1G to adavanced biofuels.

Advanced bioethanol prouction still presents uncertainities regarding its economic viability.

The integration of 2G technology into an existing 1G facility could be an excellent strategy to ease thetransition from 1G generation to advanced biofuels.

Integration of 1G and 2G technologies could result in synergies and cost saving:

• Taking adavantage of the existing product distribution and feedstock supply and storagesystems.

• Using the lignocellulosic parts of the sugar and starch crops.

• Sharing the purification areas.

• Adapting the sugar content of the fermentation by mixing the mash.

• Sharing the general infraestructure.

• Using the lignin as a renewable fuel or for high-added value compounds production.

THE BIOFIT PROJECT- BIOETHANOL INDUSTRYBIOETHANOL CASE STUDY - METHODOLOGY


Main objectives

To develop a concrete case study for the retrofitting of a 1Gbioethanol facility together with an industrial partner

To compare the retrofitting case to:

A reference case: current situation of the 1G facility

An alternative case: stand-alone 2G facility



• Current situation

• Retrofit case

• Alternative case

PROJECT DESCRIPTION

MARKET ASSESSMENT

TECHNO-ECONOMIC ASSESSMENT

SUSTAINABILITY ASSESSMENT

RISKS ANALYSIS



• Current situation

• Retrofit case

• Alternative case

PROJECT DESCRIPTION

MARKET ASSESSMENT

TECHNO-ECONOMIC ASSESSMENT

SUSTAINABILITY ASSESSMENT

RISKS ANALYSIS

Data acquisition:1G bioethanol production: real

data from Vertex Bioenergy.Advanced bioethanol production:

modelling of the retrofitting case through process simulation tools Aspen Plus V11 (Aspen Technology, Inc,USA): Generation the mass and energy

balance for calculating the raw materials, consumables, utilities and energy requirements.

THE BIOFIT PROJECT- BIOETHANOL INDUSTRYINDUSTRIAL PARTNER- VERTEX BIOENERGY


Vertex Bioenergy owns four bioethanol productionfacilities with a total capacity production of 780 Ml,

VERTEX BIOENERGY HAS ALSO A PRODUCTION CAPACITY OF ANIMAL

FEED OF 505.000 TONNE PER YEAR AND 575.000 MWH OF ELECTRICITY.

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www.biofit-h2020.eu

THE BIOFIT PROJECT- BIOETHANOL INDUSTRYINDUSTRIAL PARTNER- VERTEX BIOENERGY

CASE STUDYBiocarburantes de Castilla Y Leon (BCyL) facility, Salamanca (Spain)


CURRENT STATE

Feedstock:

Corn grain: 562,800 t /year

Products:

Ethanol : 241,670 m3/year

DDGS : 142,800 t/year

Electricity : 207,900 MWh

CO2 : 40,000 t/year



THE BIOFIT PROJECT- BIOETHANOL INDUSTRYBCyL FACILITY


THE BIOFIT PROJECT- BIOETHANOL INDUSTRYRETROFIT: CASE 1

• Production of 11,000 m3/year of advanced bioethanol sustainable using industrial residues listed in RED II

• Feedstock:

• Industrial waste from yeast production plant (10 % vol Ethanol): 20,000 m3/year

• Wine alcohol (93% vol Ethanol): 9,700 m3/year


THE BIOFIT PROJECT- BIOETHANOL INDUSTRYRETROFIT: CASE 2

• Production of 11,000 m3/year of advanced bioethanol from industrial residues and 19,000 m3/year of advanced ethanol from corn stover.

• Feedstock: Corn stover: 129,000 t/year Industrial waste (10 % vol

Ethanol): 20,000 m3/yearWine alcohol (93% vol

Ethanol): 9,700 m3/year


THE BIOFIT PROJECT- BIOETHANOL INDUSTRYALTERNATIVE SCENARIOS

• Production of 30,000

m3/year of advanced ethanol

from corn stover in a Second-

Generation facility.

• Feedstock:

Corn stover: 114,000 t/year

THE BIOFIT PROJECT- BIOETHANOL INDUSTRYOUTCOMES FROM THE STUDY SO FAR…

Key Performance Indicators (KPIs)

TechnicalIncrease in biomass converted per year

Increase in bioenergy or biofuelgenerated per year

EconomicInternal rate of return

CAPEX reduction compared toalternative

Environmental

Carbon dioxide equivalent emissionreduction

Increased efficiency of resourcesconsumption







CAPEX reduction compared to alternative

EnvironmentalCarbon dioxide equivalent emission reduction

Increased efficiency of resources consumption


Feedstock Current

situation

Case 1 Case 2

Corn (t/y) 562,800 537,184 492,937

Industrial

waste (m³/y)

- 20,000 20,000

Wine alcohol

(m³/y)

- 9,680 9,680

Corn stover

(t/y)

- - 128,680







Environmental




• Assessment in progress

• Preliminary results: better results obtained for Case 2 than for Case 1, mainly due to the lower production of DDGS in Case 1







Environmental




• Assessment in progress



Reduction of food-materials for energy purposes.

Promoting advanced bioethanol in the short-medium term

Increasing the value chains of residual feedstocks.

Diversification of feedstock

MARKET BENEFITS

POLICY RECOMMENDATIONS

The European biofuel installations are fairly new Costly investments in retrofitting measures may seem early from a

plant operator’s view.

Biofuel sector is heavily influenced by regulations The high risk of change of regulation hinders investments in the

biofuel sector.

Dedicated biofuel products at the pump It allows customer to choose sustainable fuels.

The CO2 emissions of the different fuels should be visible to the customer at the pump.

The sole responsibility for the content of this flyer lies with the authors. It does not necessarily reflect theopinion of the European Union. Neither the INEA nor the European Commission are responsible for any usethat may be made of the information contained therein.

Thank you!Contact

BIOCAR unit, CIEMAT, Spain

Ana [email protected]

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https://www.biofit-h2020.eu/

the biofit project retrofitting of the bioethanol industry

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